Nathan did you have a locker of any sort in the front diff.? I know you said you broke the alloy case, but I have not heard of anyone splitting the front diff with a locker installed.?
I thought the weak link was the 2 pinion centre which breaks teeth off and then these go into the ring and pinion and forces the diff to split when the gear mesh gets jammed up. Any photo's of your diff failures.
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No mate no locker, but i never really treated it in a way that you would expect it to snap, yeah i took it on some tough tracks, but i also have mechanical sympathy for the car and realise what to be carful of like revving it hard with a wheel in the air and have it slam down.
The first one went when i was just on an embankment testing the new tyres to see if they scrubbed and it snapped the main Pinion shaft just out side the housing in front of the tail shaft.
The one the went the other day snapped the case going diagonally through a rut, no wheels in the air and only flexing it mildly, CRACK sounding like i had just bellied out on some rocks.
I dont have any pics because 2hrs later the dumb arse P plater pulled out in front of me and wrote it off.